Painted surface sanding tool

ABSTRACT

A sanding tool is disclosed that can be used to remove a raised defect or imperfection from a painted surface. The sanding tool includes a base that defines an arcuate guide surface configured to be placed in contact with the base. In general, the base supports a sanding element for movement with respect to the base in a sanding motion. The guide surface maintains the sanding element at a desired position with respect to the painted surface while the sanding element moves in the sanding motion. An offset of the sanding element with respect to the guide surface can be selectively adjusted in certain embodiments. In some embodiments the guide surface is defined by first and second prongs spaced apart widthwise of the base, with the sanding element mounted between the prongs. A convex oscillating point sanding element is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 62/707,596, filed Nov. 11, 2017, which is hereby incorporated by reference in it is entirety.

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FIELD

This application generally relates to a sanding tool for removing a raised defect from a painted surface.

BACKGROUND

Certain painted surfaces such as auto body surfaces require a near-perfect finish. Quite often small surface imperfections occur when a small speck of dirt or dust lands, and dries, in a surface coating. Conventionally these imperfections are addressed by sanding the area of the painted surface surrounding each imperfection. Conventional sanding techniques damage portions of the painted surface that are not affected by the surface imperfection.

SUMMARY

In one or more aspects of this disclosure, a sanding tool is configured to precisely remove small imperfections (e.g., raised imperfections) in or on a painted surface. In one or more embodiments, a sanding tool provides a simple, precise, mechanized means to remove these “surface imperfections” on auto body surfaces with a minimum of effort and damage to a final coat of finish, regardless if the painted surfaces are flat, convex, or concave.

In one aspect, a sanding tool for removing a raised defect from a painted surface comprises a handheld base having a height and comprising an arcuate guide surface that is curved along the height. The guide surface is configured for engagement with the painted surface. An arm is mounted on the base for movement along the height of the base with respect to the guide surface through a range of motion. The arm is configured to mount a sanding element having a sanding surface on the arm for movement with the arm with respect to the base. The arm is configured such that the sanding element mounted on the arm is movable with respect to the arm in a sanding motion. A locking mechanism is configured to selectively lock the arm in position with respect to the base at a plurality of positions along the range of motion. The arm is configured to position the sanding element such that the sanding surface has a different offset from the arcuate guide surface along the height of the base at each of the plurality of positions of the arm.

In one or more embodiments, the guide surface includes a first surface portion on a first side of the arm and a second surface portion on a second side of the arm opposite from the first side of the arm. In certain embodiments, each of the first and second surface portions is curved along the height of the base and the first and second surface portions are aligned with one another along the height of the base.

In some embodiments, the plurality of positions of the arm includes a first position in which the arm mounts the sanding element such that the sanding surface protrudes from the guide surface along the height of the base and a second position in which the arm mounts the sanding element such that the sanding surface is aligned with the guide surface along the height of the base. The sanding surface suitably protrudes from the guide surface by less than 0.1 inches in the first position of the arm (e.g., less than 0.075 inches, less than 0.05 inches, less than 0.025 inches, less than 0.01 inches).

In certain additional or alternative embodiments, the plurality of positions of the arm includes a first position in which the arm mounts the sanding element such that the sanding surface is recessed from the guide surface along the height of the base and a second position in which the arm mounts the sanding element such that the sanding surface is aligned with the guide surface along the height of the base. The sanding surface is suitably recessed from the guide surface by less than 0.1 inches in the first position of the arm (e.g., less than 0.075 inches, less than 0.05 inches, less than 0.025 inches, less than 0.01 inches).

In an exemplary embodiment, the plurality of positions of the arm includes at least one position (e.g., more than one position) in which the arm mounts the sanding element such that the sanding surface protrudes from the guide surface along the height of the base, another position in which the arm mounts the sanding element such that the sanding surface is aligned with the guide surface along the height of the base, and at least one other position (e.g., more than one other position) in which the arm mounts the sanding element such that the sanding surface is recessed from the guide surface along the height of the base.

In one or more embodiments, the arm is pivotably mounted on the base for rotation about a pivot axis through the range of motion. A suitable locking mechanism for such an arm comprises a gear that rotates about a gear axis as the arm rotates about the pivot axis and a pawl or tooth that is selectively engageable with the gear (e.g., by movement of a slider tab positioned on the base) to prevent rotation of the gear about the gear axis. Another suitable locking mechanism for such an arm comprises a gear that rotates about a gear axis as the arm rotates about the pivot axis and a worm meshed with the gear and configured to rotate about a worm axis transverse to the gear axis. It will be appreciated that, in this embodiment, the worm provides both a locking element that locks the position of the arm when the worm is stationary and an adjustment element that adjusts the position of the arm as the worm rotates about the worm axis. Still another suitable locking mechanism for this or another type of movable arm comprises a clamping mechanism that can selectively apply a clamping force against the arm that brakes or stops movement of the arm with respect to the base. In certain embodiments, such a clamping mechanism may impart the clamping force in a similar manner to a bicycle brake.

In some embodiments, the base comprises a handle member and a guide member secured to the handle member that defines the arcuate guide surface. Suitably the guide member is formed from a non-surface-marring material. In certain embodiments, one or more guide members are the only structure that contacts the painted surface during use of the sanding tool. The guide member is, in certain embodiments, replaceable, for example, to maintain a consistent guide surface once wear or damage occurs.

The sanding motion of the sanding element mounted on the arm can comprise one of rotation, oscillation, orbital rotation, and orbital oscillation about an axis oriented generally parallel to an axis about which the guide surface is curved (e.g., rotation or oscillation about a sanding motion axis oriented generally parallel to a width of the base, generally perpendicular to a length of the arm, generally parallel to an axis about which the arm is configured to pivot with respect to the base, generally parallel to an axis about which first and second prongs of the base between which the arm and/or sanding element are received are spaced apart from one another, etc.). The sanding motion of the sanding element mounted on the arm can also comprise one of rotation and oscillation about an axis oriented generally perpendicular to an axis about which the guide surface is curved (e.g., rotation, oscillation, orbital rotation, or orbital oscillation about a sanding motion axis oriented generally perpendicular to a width of the base, generally parallel to a length of the arm, generally perpendicular to an axis about which the arm is configured to pivot with respect to the base, generally perpendicular to an axis about which first and second prongs of the base between which the arm and/or sanding element are received are spaced apart from one another, etc.).

The sanding motion can be manually driven, and the sanding tool can comprise an actuator configured to drive movement of the sanding element in the sanding motion when the sanding element is mounted on the arm and the arm is locked with respect to the base at any of the plurality of positions.

In one or more embodiments, the arm is configured to mount the sanding element such that the sanding surface has a contact area with the painted surface of less than 1.0 in², at each of the plurality of positions of the arm (e.g., less than about 0.75 in², 0.5 in², 0.25 in², 0.1 in², etc.).

In another aspect, a sanding tool for removing a raised defect from a painted surface comprises a base having a top, a bottom, a first side, a second side, a proximal end portion, a distal end portion, a height extending from the bottom to the top, a width extending from the first side to the second side, and a length extending from the proximal end portion to the distal end portion. The distal end portion of the base includes a first guide prong and a second guide prong spaced apart along the width of the base. Each of the first and second guide prongs defines a respective arcuate guide surface which curves along the height of the base. The base is configured for mounting a sanding element having a sanding surface having a curvature that is generally the same as the curvature of the guide surfaces such that the sanding surface is located between the first and second guide prongs and is generally aligned with the guide surfaces along the height of the base. The base is configured to mount the sanding element on the base such that the sanding element is movable with respect to the base in a sanding motion such that the sanding surface is configured to sand a portion of the painted surface generally aligned with the guide surfaces between the first and second guide prongs.

In certain embodiments, the sanding tool further comprises a movable arm between the first and second prongs that is configured to mount the sanding element on the base.

In one or more embodiments, the sanding motion comprises one of rotation, oscillation, orbital rotation, or orbital oscillation about a sanding motion axis and the sanding motion axis is oriented one of generally parallel to and generally perpendicular to the width of the base.

In still another aspect, a sanding element is configured to be mounted on a shaft for one of conjoint rotation and conjoint oscillation with the shaft about an axis of the shaft. The sanding element comprises a facing surface that is configured to face a work surface being sanded by the sanding element (e.g., a painted surface having a raised imperfection). The facing surface includes a sanding surface portion configured to engage the work surface and having a surface area of less than about 1.0 in² (e.g., less than about 0.75 in², 0.5 in², 0.25 in², 0.1 in², etc.). The facing surface is convex and is arcuate in cross section along substantially a full extent of the sanding element in both a vertical axis of the sanding element and a horizontal axis of the sanding element oriented perpendicular to the vertical axis.

In one or more embodiments, sanding tools of the present disclosure are used as denibbing sanders, for example, in an auto body application.

Other objects and features will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a sanding tool;

FIG. 2 is a top plan view of the sanding tool with a portion of a base housing removed to reveal interior components;

FIG. 3 is a perspective of an arm of the sanding tool;

FIG. 4 is a side elevation of the arm with a sanding wheel mounted on the arm;

FIG. 5 is a top plan view of the assembly shown in FIG. 4;

FIG. 6 is a side elevation of the sanding wheel;

FIG. 7 is a top plan view of the sanding wheel;

FIG. 8 is a side elevation of the sanding tool;

FIG. 9 is another side elevation of the sanding tool;

FIG. 10 is another side elevation of the sanding tool illustrating the sanding tool approaching contact with a painted work surface;

FIG. 11 is a top elevation of another embodiment of a sanding tool;

FIG. 12 is a side elevation of the sanding tool shown in FIG. 11 with the position of an actuator housing and sanding element illustrated in phantom;

FIG. 13 is a front elevation of the sanding element; and

FIG. 14 is a side elevation of the sanding element.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a perspective view of one embodiment of a sanding tool within the scope of the present disclosure. The illustrated tool is comprised of three major components. A base (1) comprises a housing that supports and/or encloses or contains certain mechanisms used to operate the illustrated tool. In one or more embodiments the base (1) has a top, a bottom, a first side, a second side, a proximal end portion, a distal end portion, a height extending from the bottom to the top, a width extending from the first side to the second side, and a length extending from the proximal end portion to the distal end portion. An arm (2) is pivotably (broadly, movably) attached or connected to the base (1), for example by a pivot shaft (55) (see FIG. 2; e.g., the arm is configured to pivot with respect to the base about an axis of the shaft (55)). As shown, a sanding wheel (3) (broadly, a sanding element) is mounted on the arm (2), for example by a separate shaft or axle. It will be appreciated that the sanding wheel can comprise a wearable, replaceable part. In one or more embodiments, the sanding wheel has an annular sanding surface having a grit size in an inclusive range of from about 1000 and to about 3000. The distal end portion of the base (1) is configured to define an arcuate guide surface (730) that is configured to contact a painted surface being sanded and thereby position the sanding wheel (3) with respect to the painted surface (see FIG. 10). For example, in one or more embodiments, the arcuate guide portion of the base (1) can be configured to position the sanding wheel so that the sanding wheel (3) is substantially prohibited from gouging the painted surface yet still can remove a raised imperfection on the painted surface.

FIG. 1 also highlights two components that, in the illustrated embodiment, are used to adjust a position of the sanding wheel (3) in relation to the height of the base the base (1). By adjusting the position of arm/wheel along the height of the base (1), a user can adjust an offset between the arcuate guide surface (730) and a sanding surface of the wheel, which in the illustrated embodiment comprises the annular perimeter surface of the wheel. The wheel height adjustment knob (6) is connected to a gear that interleaves with a toothed rack portion (9) of the arm (2). Turning the height adjustment knob (6) causes the arm (2) to move along the height of the base (1). In the illustrated embodiment, before the wheel height can be adjusted using the knob (6), a sliding lock button (7) must be moved away from the wheel height adjustment mechanism. After the desired wheel height is set, the spring loaded sliding lock button (7) (see spring (12) in FIG. 2), which functions as a pawl or tooth against the gear (8), is allowed to slide back to its original position, locking the wheel in place with respect to the base.

It can be seen that the sliding lock button (7) functions as a locking mechanism for locking the arm (2) in position with respect to the base to fix an offset between a sanding surface of the wheel (3) and the arcuate guide surface (730) of the base (1). It will be appreciated that other types of locking mechanisms (e.g., worm gears, braking clamps, etc.) can be used in place of or as a supplement to the illustrated locking mechanism without departing from the scope of the invention. In one or more embodiments, a locking mechanism within the scope of this disclosure is configured to lock the arm at a plurality of closely spaced positions along the height of the base. For example, at least some of the positions at which the arm can be locked in place using the locking mechanism are spaced along the height of the base by less than 0.1 in, less than 0.075 in, less than 0.05 in, less than 0.025 in, or less than 0.01 in, in certain embodiments.

Referring again to FIG. 1, in one or more embodiments, the base comprises a handle member and one or more base guards (30) (each, broadly, a guide member) attached to the handle member to define the arcuate guide surface (730). In the illustrated embodiment, the base (1) comprises two base guards located on the bottom surface of the base (1). In the illustrated embodiment, the handle member of the base (1) comprises first and second prongs spaced apart along the width of the base such that the arm (1) and/or the sanding wheel (3) is received in a gap between the prongs. Suitably, one base guard (30) is mounted on each of the prongs to define a portion of the arcuate guide surface (730) located at the respective prong. Thus, in the illustrated embodiment, the base guards (30) define a majority or all of the arcuate guide surface (730) of the base (1). These base guards can serve two purposes in the illustrated embodiment. The base guards (30) are made from plastic such as nylon or other non-surface-marring material (e.g., a material that is softer than material forming other exterior portions of the base), which does not damage a painted surface when placed in contact with or slid along the painted surface. The base guards (30) also protect the tool itself in some instances if it is dropped on a hard surface. If the base guards (30) are damaged as a result of dropping the device or any other way, the base guards can be replaced. This way the portion of the device that contacts a painted surface during usage is free of imperfections that may cause damage to a painted surface.

The illustrated base (1) has cooling vents (29) on the top surface and an on/off switch (27) that operates an actuator (4) such as an electric motor powered by a battery (5) or pneumatic motor that drives the sanding wheel (3) to move relative to the base and the arm in a sanding motion. In the illustrated embodiment, the sanding motion comprises rotation about the axis of the shaft (18), which is oriented generally parallel to the width of the base, generally parallel to the pivot axis of the arm (2), generally perpendicular to the length of the arm, generally parallel to an axis CA (FIG. 8) about which the arcuate guide surfaces (730) are curved, etc. In other embodiments a similar sanding wheel could be configured to oscillate about the same axis or another (e.g., perpendicular) axis.

FIG. 2 is a top view of the tool where the top surface is broken away to show an exemplary embodiment of internal components of a powered version of the sander that uses an actuator (4) to drive the sanding wheel (3) to move the sanding when in a sanding motion. It will be understood that other powered sanding tools can have other configurations without departing from the scope of the invention. Moreover, it will be understood that the sanding element could be manually moved in a sanding motion with respect to the base and/or arm of the sanding tool without departing from the scope of the invention.

Located inside the illustrated base (1), the on/off switch (27) is connected to a rechargeable battery (5) via wiring (28). The rechargeable battery (5) is connected to an AC input port (23) via wiring (24). The battery (5) is attached to a motor (4) via wiring (26). The motor (4) has a motor shaft (14) extending from one end. A motor shaft cog or drive gear (15) is attached to the motor shaft (14). The motor shaft cog (15) is meshed with a connecting gear (32). This connecting gear (32) is meshed with a cog (35) attached to the drive axle (55). The drive axle (55) travels through a hole in the arm (22). A drive belt cog (31) is attached to the other end of the drive axle (55). A rubber drive belt (16) connects the drive belt cog (31) to the wheel axle cog (17). A recess in the base (19) provides clearance for the rubber drive belt to operate. A wheel axle (18) is attached to the wheel axle cog (17). The sanding wheel (3) is attached to the wheel axle (18). The components connecting the motor (4) to the sanding element (3) so that the motor can drive rotation, oscillation, orbital rotation, or orbital oscillation of the sanding element may be broadly referred to as a drive linkage. It will be appreciated that various embodiments of drive linkages may be used without departing from the scope of the invention.

As mentioned above, position of arm (2) is adjustable. Turning the height adjustment knob (6) provides this adjustability. In the illustrated embodiment, the user must move the sliding lock button (7) away from the height adjustment knob (6) to disengage the locking mechanism before turning the height adjustment knob (6). Moving the sliding lock button removes the brake component (16) and allows the height adjustment gear (8) to actuate the arm (2) by mating with the geared portion of arm (9). The wheel height adjustment knob (6) is attached to the height adjustment gear (8) via a shaft (10).

FIG. 3 is a perspective view of the arm (2). The arm (2) has a hole (22) that allows the arm to be pivotally attached to the base of the tool. A forward portion of the arm (2) defines a toothed rack. The wheel axle fits into the axle hole in the arm portion (40). It can be seen that the illustrated arm (2) has a generally forked construction with two prongs spaced apart along the width of the base (1) in use. The sanding element (3) is configured to be mounted on the arm between the spaced apart arm portions and likewise between the spaced apart prongs of the base (1). Thus the sanding element can sand a portion of a work surface or painted surface located between the prongs of the base (1) and the spaced apart portions of the arm (2), in certain embodiments. It will be understood that movable and lockable arms for supporting a sanding element on a base can have configurations other than what is shown in the drawings without departing from the scope of the invention.

FIG. 4 is a side view of the arm (2) with the sanding wheel (3). The sanding wheel has wheel cavities (33) evenly placed on the both the front and back surfaces of the sanding wheel. The cavities (33) are thought to provide greater visibility of the work surface as the wheel is rotated during sanding. Sanding wheels that are free of cavities can also be used without departing from the scope of the invention.

FIG. 5 is a top view of the arm (2) with the sanding wheel (3) attached via the wheel axle (18). The wheel axle cog (17) is attached to wheel axle (18). FIG. 5 also illustrates that the wheel cavities (33) on one side of the sanding wheel are symmetrically opposed to the wheel cavities on the opposite side of the sanding wheel.

FIG. 6 is a front view of the sanding wheel (3). An axle hole (44) is located in the center of the wheel. There are equally spaced wheel cavities (33) on both the front and back surfaces of the sanding wheel in the illustrated embodiment.

FIG. 7 is a side view of the sanding wheel. The equally spaced wheel cavities (33) on the front surface of the sanding wheel are symmetrically offset to the equally spaced wheel cavities on the back surface of the sanding wheel. This offset produces a wave form pattern of coated abrasive material (21) around the perimeter of the sanding wheel. The side profile of the outer perimeters of the sanding wheel (3) have a radius portion (37) on the wave form pattern of coated abrasive.

FIG. 8 is a front view of the tool. This view shows the height adjustment knob (6), the sliding lock button (7), and the on/off switch (27). This front view also illustrates one of the removable base guards (30) attached to the radius and forward portions of the base of the tool (1).

FIG. 9 is a back view of the tool. This view shows an opening on the back surface of the base (65). This opening (65) shows the rubber drive belt (16) that drives the sanding wheel (3). The AC input port (23) is located on the back surface of the base (1). There is another replaceable base guard (30) on the lower and forward radius portions on this side of the base.

FIG. 10 is a side view of the tool being held at an angle to a painted surface (80). This view shows the base guards (30) in contact with the painted surface (80). The tool is designed so that the majority of time the user will place the lower portion of radius of the base (1) on the painted surface near to the paint imperfection to be removed.

For example, when a user of the sanding tool identifies a raised surface imperfection on a painted surface, the user can position the sanding tool so that the portions of the arcuate guide surface (730) defined by the prongs of the base (1) contact the painted surface on opposite sides of the imperfection. Depending on the nature of the surface that is affected by the imperfection, the user may need to adjust the offset between the sanding surface of the sanding wheel (3) and the arcuate guide surface (730) of the base (1). The goal may be to position the sanding wheel (3) for removing the raised surface imperfection substantially without forming a recess in the painted surface. For example, if the imperfection is near a convex portion of the painted surface, the user may adjust and lock the arm (2) to position the sanding wheel (3) such that the sanding surface is slightly recessed (e.g., by less than 0.1 in, less than 0.075 in, less than 0.05 in, less than 0.025 in, less than 0.01 in) with respect to the arcuate guide surface of the base (1). If the imperfection is near a concave portion of the painted surface, the user may adjust and lock the arm (2) to position the sanding wheel (3) such that the sanding surface protrudes slightly (e.g., by less than 0.1 in, less than 0.075 in, less than 0.05 in, less than 0.025 in, less than 0.01 in) with respect to the arcuate guide surface (730) of the base (1). If the surface is substantially flat, the user may adjust and lock the arm (2) to position the sanding wheel (3) such that the sanding surface is aligned with the arcuate guide surface (730). To that end, the arcuate sanding surface suitably has a curvature that is about the same as a portion of the arcuate guide surface (730) with which that sanding surface is aligned in the non-offset position. With the arcuate guide surface (730) held against the painted surface, the user drives the sanding element (3) in the sanding motion to remove the raised surface imperfection. Suitably, the sanding element (3) is configured to have a very small contact area with the painted surface (e.g., less than 1.0 in², 0.75 in², 0.5 in², 0.25 in², 0.1 in², etc.) such that only minimal touch up work is required after the raised surface imperfection has been removed.

Referring to FIGS. 11-14 another embodiment of a sanding tool is generally indicated at reference number 110. The sanding tool 110 comprises a base 112 having a top, a bottom, a first side, a second side, a proximal end portion, a distal end portion, a height extending from the bottom to the top, a width extending from the first side to the second side, and a length extending from the proximal end portion to the distal end portion. The distal end portion of the base 112 includes a first guide prong 114A and a second guide prong 114A spaced apart along the width of the base. Each of the first and second guide prongs 114A, 114B defines a respective arcuate guide surface 116 which curves along the height of the base 112. The base 112 is configured for mounting a sanding element 120 having a sanding surface having a curvature that is the same as the curvature of the guide surfaces 116 (see FIG. 12) such that the sanding surface is located between the first and second guide prongs 114A, 114B and is generally aligned with the guide surfaces along the height of the base. The base 112 is configured to mount the sanding element 120 on the base such that the sanding element is movable with respect to the base in a sanding motion such that the sanding surface is configured to sand a portion of the painted surface generally aligned with the guide surfaces 116 between the first and second guide prongs 114A, 114B. In one or more embodiments, the sanding element 120 can be mounted on an arm that is movable with respect to the base 112 along the height of the base to adjust an offset between the sanding surface of the sanding element and the arcuate guide surface 116.

In the illustrated embodiment, the sanding motion comprises oscillation about an axis SA oriented generally perpendicular to the width of the base 112 (e.g., an axis oriented generally perpendicular to an axis CA (FIG. 12) about which the guide surface is curved, etc.). The sanding motion could also comprise rotation, orbital rotation, or orbital oscillation about the sanding axis in one or more embodiments. The sanding element 120 is configured to be mounted on a shaft 122 for one of conjoint oscillation with the shaft about an axis of the shaft. In one or more embodiments, the tool 110 comprises an actuator that is configured to drive oscillation (e.g., the sanding motion) of the sanding element 120 when the sanding element is mounted on the base. In certain embodiments, the sanding motion can be manually driven in oscillation or another type of sanding motion.

The sanding element 120 is formed from one or more pieces of material that define a facing surface 130, which in one embodiment, has a substantially self-retaining from. Suitably, at least a portion of the facing surface is coated or is otherwise textured to have a grit size in an inclusive range of from about 1000 and to about 3000. The facing surface 130 is configured to face a work surface being sanded by the sanding element 120 (e.g., a painted surface having a raised imperfection). The facing surface includes a sanding surface portion 130A configured to engage the work surface and having a surface area of less than about 1.0 in² (e.g., less than about 0.75 in², 0.5 in², 0.25 in², 0.1 in², etc.). The facing surface 120 is convex and is arcuate in cross section along substantially a full extent of the sanding element along both a vertical axis VA of the sanding element and a horizontal axis HA of the sanding element oriented perpendicular to the vertical axis. As shown in FIG. 12, at least the sanding surface portion 120A of the facing surface 120 has a curvature in a vertical plane that generally matches the curvature of the arcuate guide surface 116 of the base 112.

Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.

When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above constructions, products, and methods, without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 

What is claimed is:
 1. A sanding tool for removing a raised defect from a painted surface, the sanding tool comprising: a handheld base having a height and comprising an arcuate guide surface that is curved along the height, the guide surface being configured for engagement with the painted surface; an arm mounted on the base for movement along the height of the base with respect to the guide surface through a range of motion, the arm being configured to mount a sanding element having a sanding surface on the arm for movement with the arm with respect to the base, the arm being configured such that the sanding element mounted on the arm is movable with respect to the arm in a sanding motion; and a locking mechanism configured to selectively lock the arm in position with respect to the base at a plurality of positions along the range of motion, wherein the arm is configured to position the sanding element such that the sanding surface has a different offset from the arcuate guide surface along the height of the base at each of the plurality of positions of the arm.
 2. A sanding tool as set forth in claim 1, wherein the guide surface includes a first surface portion on a first side of the arm and a second surface portion on a second side of the arm opposite from the first side of the arm.
 3. A sanding tool as set forth in claim 2, wherein each of the first and second surface portions is curved along the height of the base and the first and second surface portions are aligned with one another along the height of the base.
 4. A sanding tool as set forth in claim 1, wherein the plurality of positions of the arm includes a first position in which the arm mounts the sanding element such that the sanding surface protrudes from the guide surface along the height of the base and a second position in which the arm mounts the sanding element such that the sanding surface is aligned with the guide surface along the height of the base.
 5. A sanding tool as set forth in claim 4, wherein the sanding surface protrudes from the guide surface by less than 0.1 inches in the first position of the arm.
 6. A sanding tool as set forth in claim 1, wherein the plurality of positions of the arm includes a first position in which the arm mounts the sanding element such that the sanding surface is recessed from the guide surface along the height of the base and a second position in which the arm mounts the sanding element such that the sanding surface is aligned with the guide surface along the height of the base.
 7. A sanding tool as set forth in claim 6, wherein the sanding surface is recessed from the guide surface by less than 0.1 inches in the first position of the arm.
 8. A sanding tool as set forth in claim 1, wherein the arm is pivotably mounted on the base for rotation about a pivot axis through the range of motion.
 9. A sanding tool as set forth in claim 8, wherein the locking mechanism comprises a gear that rotates about a gear axis as the arm rotates about the pivot axis and a pawl that is selectively engageable with the gear to prevent rotation of the gear about the gear axis.
 10. A sanding tool as set forth in claim 8, wherein the locking mechanism comprises a gear that rotates about a gear axis as the arm rotates about the pivot axis and a worm meshed with the gear and configured to rotate about a worm axis transverse to the gear axis.
 11. A sanding tool as set forth in claim 1, wherein the base comprises a handle member and a guide member secured to the handle member, the guide member defining the arcuate guide surface.
 12. A sanding tool as set forth in claim 11, wherein the guide member is formed from a non-surface-marring material.
 13. A sanding tool as set forth in claim 11, wherein the guide member is replaceable.
 14. A sanding tool as set forth in claim 1, wherein the sanding motion comprises one of rotation and oscillation about an axis oriented generally parallel to an axis about which the guide surface is curved.
 15. A sanding tool as set forth in claim 1, wherein the sanding motion comprises one of rotation and oscillation about an axis oriented generally perpendicular to an axis about which the guide surface is curved.
 16. A sanding tool as set forth in claim 1, wherein the arm is configured to mount the sanding element such that the sanding surface has a contact area with the painted surface of less than 1.0 in² at each of the plurality of positions of the arm.
 17. A sanding tool for removing a raised defect from a painted surface, the sanding tool comprising: a base having a top, a bottom, a first side, a second side, a proximal end portion, a distal end portion, a height extending from the bottom to the top, a width extending from the first side to the second side, and a length extending from the proximal end portion to the distal end portion, the distal end portion of the base including a first guide prong and a second guide prong spaced apart along the width of the base, each of the first and second guide prongs defining a respective arcuate guide surface which curves along the height of the base, wherein the base is configured for mounting a sanding element having a sanding surface having a curvature that is generally the same as the curvature of the guide surfaces such that the sanding surface is located between the first and second guide prongs and is generally aligned with the guide surfaces along the height of the base, wherein the base is configured to mount the sanding element on the base such that the sanding element is movable with respect to the base in a sanding motion such that the sanding surface is configured to sand a portion of the painted surface generally aligned with the guide surfaces between the first and second guide prongs.
 18. A sanding tool as set forth in claim 17, wherein the sanding tool further comprises a movable arm between the first and second prongs and configured to mount the sanding element on the base.
 19. A sanding tool as set forth in claim 17, wherein the sanding motion comprises one of rotation and oscillation about a sanding motion axis and the sanding motion axis is oriented one of generally parallel to and generally perpendicular to the width of the base.
 20. A sanding element configured to be mounted on a shaft for one of conjoint rotation and conjoint oscillation with the shaft about an axis of the shaft, the sanding element comprising a facing surface that is configured to face a work surface being sanded by the sanding element, the facing surface including a sanding surface portion configured to engage the work surface and having a surface area of less than about 1.0 in², the facing surface being convex and being arcuate in cross section along substantially a full extent of the sanding element in both a vertical axis of the sanding element and a horizontal axis of the sanding element oriented perpendicular to the vertical axis. 